Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/49—Phosphorus-containing compounds
  • C08K5/51—Phosphorus bound to oxygen
  • C08K5/52—Phosphorus bound to oxygen only
  • C08K5/521—Esters of phosphoric acids, e.g. of H3PO4
  • C08K5/523—Esters of phosphoric acids, e.g. of H3PO4 with hydroxyaryl compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/49—Phosphorus-containing compounds
  • C08K5/51—Phosphorus bound to oxygen
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
  • C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
  • C08L71/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
  • C08L71/12—Polyphenylene oxides
  • C08L71/123—Polyphenylene oxides not modified by chemical after-treatment

Definitions

• the present invention relates to flame retarded polymer composition for molding applications which polymer composition comprises in admixture a thermoplastic molding resin and a particular phosphate flame retardant.
• the phosphate fame retardant comprises a combination or mixture of two phosphates, namely a low molecular weight and a high molecular weight phosphate and to articles molded with the composition of this invention.
• phosphates as flame retardants for polymers or thermoplastic molding resins particularly such monophosphates as triphenyl phosphate, tricresyl phosphate, diphenylcresyl phosphate and the like.
• monophosphate esters tend to migrate to the surface when the thermoplastic composition is molded such as injection molding causing so called “juicing.” Juicing is where the additive migrates to the surface of the molded article during molding.
• other flame retardants need to be employed with the momophosphate esters, particularly halogen containing flame retardants, Halogen flame retardants are undesirable because of the environment concerns and the pitting of the mold surface.
• halogen flame retardants are undesirable because of the environment concerns and the pitting of the mold surface.
• if high concentrations of the particular phosphate esters are employed a decrease in heat resistance and impact resistance can result.
• the object of the present invention is to provide a thermoplastic molding composition having good flame retardant properties without the use of halogenated flame retardant.
• a further object of the present invention is to provide a flame retardant composition having good heat deflection temperature and impact resistance.
• Another object of the present invention is to provide a flame retardant molded thermoplastic article prepared from the composition of this invention and having good mechanical properties of heat deflection and impact resistance.
• This invention is directed to a thermoplastic resin molding composition having excellent flame retardant properties using a non halogenated flame retardant while maintaining good mechanical properties of heat deflection temperature, impact resistance and flow.
• the flame retardant employed herein is a combination of a low molecular weight phosphate and a high molecular weight phosphate.
• the low molecular weight phosphate has a molecular weight of at least about 500 and preferably about 500 to about 2000.
• the high molecular weight phosphate has a molecular weight of at least about 2300 and preferable about 2300 to about 11,000.
• the invention is directed to a flame retardant thermoplastic molding composition and to articles molded therefrom.
• the flame retardant thermoplastic molding composition comprises in admixture a thermoplastic molding resin and a flame retardant additive comprising in combination a low molecular weight and a high molecular weight phosphate.
• the phosphates employed herein are preferably represented by the following formula:
• R 1 , R 2 , R 3 and R 4 are independently selected from the group consisting of an aryl or an alkarly group
• X is an arylene group
• m is an integer of from 0 or 1.
• the phosphate is an oligomeric phosphate wherein n is an integer of from 1 to 5.
• the low molecular weight phosphate of this invention with or without this above formula has a molecular weight of at least about 500 and preferable about 500 to about 2000 wherein n is 1 to 5.
• the high molecular weight phosphate of this invention with or without this above formula has a molecular weight of at least about 2300 and preferably about 2300 to about 11,000 wherein n is an integer of from about 6 to 35. More preferably, the high molecular weight phosphate of this invention has a molecular weight of at least about 5000 and most preferably at least about 7500. It is important that the molecular weight of the low molecular weight phosphate does not overlap the molecular weight of the high molecular weight phosphate.
• the aryl groups may be aryl or an alkyl substituted aryl group thus alkaryl groups.
• the aryl groups are independently selected from cresyl, phenyl, xylenyl, propylphenyl and butylphenyl groups.
• the arylene group is derived from a dihydric compound and is preferable resorcinol, hydroqinone and bisphenol-A. More particularly the aryl group (R 1 , R 2 , R 3 and R 4 ) is phenyl and the more particular arylene group is bisphenol-A.
• the more preferred low molecular weight phosphate is bisphenol-A tetraphenyl diphosphate wherein n is 1, m is 1, X is bisphenol-A and the R's are phenyl with this more preferred low molecular weight phosphate having a molecular weight of about 693.
• the most preferred is bisphenol-A phenyl polyphosphate having a molecular weight of about 10,056.
• the R's are phenyl groups, X is bisphenol-A, m is 1 and n is about 32.
• the thermoplastic resin employed herein can be any of the thermoplastic molding resins that can be molded by injection molding, compression molding, transfer molding, extrusion blow molding or profile extrusion.
• the preferred thermoplastic molding resins are aromatic polycarbonates, high impact polystyrenes, styrene containing copolymers and styrene containing graft copolymers such as acrylonitrile-butadiene-styrene (ABS) resins, polyphenylene ether resins, polyalkylene terephthalate resins such as polybutylene terephthalate, polyethylene terephphalate, and polypropylene terephthalate resins, polyether imide resins, polyether imide ester resins, polyamide resins, polyphenylsulfide resins, polyphenyl sulfones, polyimide resins and mixtures thereof.
• the most preferred resins are aromatic polycarbonates, blends of aromatic polycarbonates and ABS, blends of aromatic
• the amount of phosphate employed can be that amount of phosphate which renders the thermoplastic molding resin composition flame retardant while maintaining good properties of heat deflection temperature, impact resistance and flow.
• the composition of the invention contains about 3 to about 25 weight percent of the phosphate flame retardant based on the total weight of thermoplastic resin and phosphate flame retardant and preferably about 5 to about 20 weight percent thereof.
• the flame retardant of this invention is a combination of a low molecular weight and a high molecular weight phosphate.
• the flame retardant consists essentially of about 10 to about 90 weight % of the low molecular weight phosphate and correspondingly 90 to about 10 weight % of the high molecular weight phosphate based on the weight of the flame retardant.
• the combination of phosphates consists essentially of about 40 to about 70 weight % of the low molecular weight phosphate and correspondingly about 60 to about 30 weight % of the high molecular weight phosphate.
• additives may be employed with the composition of this invention such as other flame retardant enhancing additives, reinforcing additives such as glass fibers, other mineral additives such as mica, talc, oxides, including plasticizers, light and heat stabilizer, processing aides, impact modifiers, mold release agents, etc.
• compositions of this invention produce molded articles having a combination of excellent properties, depending on the thermoplastic resin employed and the application for the molded article.
• molded articles from the composition of this invention have a notched Izod of at least about 5.0 ft.-lbs/in., as determined in accordance with ASTM D 256, a heat deflection temperature under load of at least about 200° F. as determined in accordance with ASTM D 648, a flow of at least about 18′′ by the spiral flow measurement of a 1 ⁇ 8′′ thick channel and a flammability rating of at least V1 as determined in accordance with Underwriters Laboratory Bulletin UL 94.
• an injection molded article may preferably have a notched Izod of at least about 7.0 ft.-lbs/in., a heat deflection temperature under load of at least about 200° F., a flow of at least about 25.0′′ and a UL 94 rating of at least V1.
• an injection molded article may preferably have a heat deflection temperature of at least about 200° F., a flow of at least about 15′′ and a UL 94 rating of at least V1.
• PC an aromatic polycarbonate derived from bisphenol-A and a carbonyl chloride (phosgene) having a weight average molecular weight of about 22,000 and an intrinsic viscosity (I.V.) of about 0.40 dl/g as measured in methylene chloride at 25° C.
• HRG a high rubber graft copolymer prepared by grafting a styrene-acrylonitrile onto a butadiene rubber in a 50/50 ratio
• Phosphate 1 a mixture of several oligomeric diphosphates based on resorcinol
• Phosphate 2 Bisphenol-A tetraphenyl diphosphate having a molecular weight of about 693.
• Phosphate 3 Bisphenol-A phenyl polyphosphate having a molecular weight of about 10,056.
• Blend 1 2 3 4 HRG 81.05 80.05 80.05 80.05 Phosphate 1 11 Phosphate 2 10 6 Phosphate 3 11 5 PTFE .2 .2 .2 .2 Additives .95 .95 .95 .95 PROPERTIES Notched Izod (ft-lb/in) 9.0 7.1 8.6 2.3 HDT (° F.) 204 236 214 188 Flow Channell (′′) 28 25.5 29.75 32.5 UL 94 ( ⁇ fraction (1/16) ⁇ ′′) V0 V2 V0 V0 Additives - stabilizer package of a hindered phenol, a phosphite and a lubricant
• Example 1 was repeated except that the formulations employed herein are as reported in Table 2 below.
• the polyphenylene ether employed had an I.V. of about 0.46 dl/g and was produced by General Electric Company.
• the high impact polystyrene (HPS) was produced by GE-Huntsman Co., Selkirk, N.Y., and had a weight average molecular weight of about 200,000 and a rubber content of about 101 ⁇ 2 weight % based on the weight of the high impact polystyrene.
• the properties obtained were determined employing the same test procedures employed in Example 1. The results obtained are set forth in Table 2 below.
• Blend 1 Polyphenylene ether 50.5 50.5 High impact PS (HPS) 28 28 Phosphate 1 16.7 10.7 Phosphate 3 0 6.0 Polyethylene 1.25 1.25 Additives 1.0 1.0 Impact modifier 2.55 2.55 PROPERTIES HDT (° F.) 193 228 Flow Channel (′′) 20.5 19.75 UL 94 V0 V0 PS - Polystyrene Impact modifier - a styrene-butadiene block copolymer produced by Shell Chemical Co., Kraton G1650 Additives - a stabilizer package of a phosphite, an oxide and a sulfide Polyethylene - a mold release agent

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• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Polymers With Sulfur, Phosphorus Or Metals In The Main Chain (AREA)

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Citations (26)

• 1996
  • 1996-03-04 TW TW085102633A patent/TW360681B/zh not_active IP Right Cessation
  • 1996-05-07 SG SG1996012333A patent/SG67965A1/en unknown
  • 1996-05-30 JP JP13562196A patent/JP3961046B2/ja not_active Expired - Fee Related
  • 1996-05-31 ES ES96303937T patent/ES2149428T3/es not_active Expired - Lifetime
  • 1996-05-31 EP EP96303937A patent/EP0747424B1/en not_active Expired - Lifetime
  • 1996-05-31 DE DE69610020T patent/DE69610020T2/de not_active Expired - Lifetime
  • 1996-06-03 CN CNB961081074A patent/CN1140588C/zh not_active Expired - Fee Related
  • 1996-06-05 KR KR1019960020154A patent/KR100445084B1/ko not_active IP Right Cessation
• 1997
  • 1997-04-29 US US08/841,028 patent/US6815476B1/en not_active Expired - Fee Related

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